Material-Agnostic Zero-Shot Thermal Inference for Metal Additive Manufacturing via a Parametric PINN Framework
Authors: Hyeonsu Lee, Jihoon Jeong
Organizations: Wm Michael Barnes ’64 Department of Industrial and Systems Engineering Texas A&M University College Station, TX 77843, USA
Abstract
Accurate thermal modeling in metal additive manufacturing (AM) is essential for understanding the process-structure-performance relationship. While prior studies have explored generalization across unseen process conditions, they often require extensive datasets, costly retraining, or pre-training. Generalization across different materials also remains relatively unexplored due to the challenges posed by distinct material-dependent thermal behaviors. This paper introduces a parametric physics-informed neural network (PINN) framework for zero-shot generalization across arbitrary materials without labeled data, retraining, or pre-training. The framework adopts a decoupled parametric PINN architecture that separately encodes material properties and spatiotemporal coordinates, fusing them through conditional modulation to better align with the multiplicative role of material parameters in the governing equation and boundary conditions. Physics-guided output scaling derived from Rosenthal's analytical solution and a hybrid optimization strategy are further incorporated to enhance physical consistency, training stability, and convergence. Experiments on bare plate laser powder bed fusion (LPBF) across diverse metal alloys, including both in-distribution and out-of-distribution cases, demonstrate effective zero-shot generalizability along with superior training efficiency. Specifically, the proposed framework achieved up to a 64.2% reduction in relative L2 error compared to the non-parametric baseline while surpassing its performance within only 4.4% of the baseline training epochs. Ablation studies confirm that the proposed framework's components are broadly applicable to other PINN-based approaches. Overall, the proposed framework provides an efficient and scalable material-agnostic solution for zero-shot thermal modeling, contributing to more flexible and practical deployment in metal AM.
Autonomous space systems operating in extreme thermal environments require accurate and efficient thermal modeling to support both pre-mission system design and onboard autonomy. For lunar rovers, large temperature gradients, radiative heat transfer, and variable surface conditions make reliable thermal prediction especially challenging. High-fidelity physics-based simulations provide accurate results but are computationally expensive, while simplified models and lookup-table approach often lack sufficient accuracy. Physics-informed machine learning (PIML) offers a promising alternative by combining data-driven models with embedded physical knowledge. This paper presents a PIML framework for thermal analysis of a simplified lunar rover with internal heat sources, where machine learning enables environment-adaptive coarse meshing. The proposed architecture integrates a transfer neural network (TNN) that adaptively determines 3D finite-difference nodalization based on thermal loads and initial conditions, enabling more accurate coarse-mesh calculations. A differentiable finite-difference thermal simulator is embedded within the framework to enforce physical consistency and support efficient training, while an upscaling layer reconstructs high-resolution temperature fields from the coarse-grid solution. The proposed PIML approach is evaluated against high-fidelity fine-mesh simulations, low-fidelity fixed coarse-mesh models, and a purely data-driven artificial neural network (ANN). Results show that the PIML framework improves prediction accuracy by 50% and 39% relative to the coarse-mesh physics model and ANN model, respectively, while maintaining physically consistent thermal distributions. Computationally, the framework is also 3x faster than high-fidelity simulations, demonstrating an effective balance between accuracy and efficiency for thermal modeling of lunar rover systems.
Physics-informed neural networks (PINNs) approximate solutions of partial differential equations (PDEs) by embedding physical laws into the loss function. In parameterized PDE families, variations in coefficients or boundary/initial conditions define distinct tasks. This makes training individual PINNs for each task computationally prohibitive, while cross-task transfer can be sensitive to task heterogeneity. While meta-learning can reduce retraining cost, existing methods often rely on a single global initialization and may suffer from negative transfer, particularly under feature-scarce coordinate inputs and limited training-task availability. We propose the Learning-Affinity Adaptive Modular Physics-Informed Neural Network (LAM-PINN), a compositional framework that leverages task-specific learning dynamics. LAM-PINN combines PDE parameters with learning-affinity metrics from brief transfer sessions to construct a task representation and cluster tasks even with coordinate-only inputs. It decomposes the model into cluster-specialized subnetworks and a shared meta network, and learns routing weights to selectively reuse modules instead of relying on a single global initialization. Across three PDE benchmarks, LAM-PINN achieves an average 19.7-fold reduction in mean squared error (MSE) on unseen tasks using only 10% of the training iterations required by conventional PINNs. These results indicate its effectiveness for generalization to unseen configurations within bounded design spaces of parameterized PDE families in resource-constrained engineering settings.
We propose a self-supervised physics-informed neural network (PINN) framework that adaptively balances physics-based and data-driven supervision for scientific machine learning under data scarcity. Unlike prior PINNs that rely on fixed or heuristic weighting of physics residuals and data loss, our approach introduces a learnable blending neuron that dynamically adjusts the relative contribution of each term based on their uncertainties. This mechanism enables stable training and improved generalization without manual tuning. To further enhance efficiency, we integrate a transfer learning strategy that reuses representations from related domains and adapts them to new physical systems with limited data. We validate the framework for the prediction of heat transfer in liquid-metal miniature heat sinks using only 87 CFD datapoints, where the adaptive PINN achieves an error <8%, outperforming shallow neural networks, kernel methods, and physics-only baselines. Our framework provides a general recipe for embedding physics adaptively into neural networks, offering a robust and reproducible approach for data-scarce problems across various scientific domains, including fluid dynamics and material modeling.